Pickle manufacturing

ABSTRACT

Separate streams of saturated brine and a dose mix of liquid sugar or dextrose, water and additional ingredients useful in curing, are strained, metered and combined whereafter the combined stream is cooled and stored against need in curing operations.

Unlted States Patent 1 1 3,717,479 Connick 1 Feb. 20, 1973 541 PICKLEMANUFACTURING 3,139,347 6/1964 Sairet al. .99/139 ....99 222 [75]Invent: Francis 0mm", Dmlmers i322 ....99/159 Grove, 3,252,808 5/1966Sair et al. ..99/222 [73] Assignee: Swift & Company, Chicago, Ill.

[22] Filed: Dec. 1, 1970 Primary ExaminerHyman Lord Appl. No.: 94,064

References Cited UNITED STATES PATENTS 6/1962 Schleigh et al. ..99/222Attorney-Edward T. McCabe and Charles E. Bouton ABSTRACT 4 Claims, 1Drawing Figure PATENTEDFEBZOIISB 3,717, 479

INVENTUF? FRANK/5 GLENN [UNIV/CK ATPY PICKLE MANUFACTURING Thisinvention relates to the manufacture of liquid curing pickle formulas;and more precisely concerns an improved method and system of apparatusfor semi-automatically mixing and proportioning pickle solutioningredients to maintain a volume of finished pickle formula for use incuring operations.

Liquid curing pickle formulas have previously been prepared in largebatches and then set aside for cooling for a period of 1 or 2 days.Various of theingredients required in pickle formulas present solubilityproblems and under some conditions cannot be dissolved with rapidity ormaximum quantity in aqueous solutions containing other ingredients.Phosphate salts are known to present many problems of this nature.Furthermore, when preparing large volumes of liquid pickle formula on aday-to-day or every-other-day basis, it has been difficult to accuratelyapportion water and all of the necessary ingredients in exactly the sameamounts for each batch. Because of the resultant slight variation iningredients from batch to batch, it has been necessary in the subsequentcuring operations to establish a minimum required curing time based uponthe least desirable curing formulation that is likely to be experienced.With the likelihood of inaccuracies in repeating the same formulationday after day it has thus been necessary to require relatively longcuring times for the ultimate product. However, if it could be assuredthat an optimum curing pickle formulation could be replicated withaccuracy and containing the maximum quantities of curing salts, thesubsequent curing times could be reduced, with confidence, to theminimum time required by the optimum formula.

Accordingly, it is an object of the present invention to provide animproved method and apparatus to semiautomatically apportion and mixcuring formula in-- gredients so as to enable a reduction in curingtime.

Another object of the present invention is to provide an improved methodand apparatus for manufacturing a liquid pickle formulation that willreduce the manual labor required.

It is still another object of the present invention to provide a methodand apparatus for preparing liquid pickle formulation in the quantitiesand at intervals consistent with current needs of the curing operations.

Yet another object of the present invention is to provide an improvedmethod and apparatus for preparing a liquid pickle formulation whereinthe solubilizing of the various ingredients is facilitated under optimumconditions.

Still another object of the present invention is to provide an improvedmethod and apparatus for producing liquid pickle formulations andrapidly chilling same on a continuous flow basis.

Still another object of the present invention is to provide an improvedsystem of apparatus for producing liquid pickle formulations which maybe readily cleaned and sanitized.

Basically, the present invention involves a method wherein salt iscontinuously exposed to water to produce a saturated brine that is thenstored. Separately, a supply of liquid dextrose or liquid sugar ismaintained in a heated condition and measured quantities thereof areperiodically introduced into a mixing zone with measured quantities ofwater. The dextrose and water are agitated and additional formulaingredients such as phosphates and curing salts are added in measuredweights, either in dry form or in preprepared solutions, and furthermixed with the dextrose and water to produce a dose mix. Periodicallyand simultaneously, quantities of both saturated brine and dose mix arewithdrawn in separately controlled streams bearing a desired ratio toone another and the separate streams are subsequently mixed to form asingle flow of pickle formula. The pickle formula is then cooled andstored in a holding zone against demand from which it may be pumped tocuring operations.

A system of apparatus devised for carrying out the method comprisesstorage tanks for. both brine and dextrose and mixing tank and means tosupply dose ingredients thereto. The mixing tank and brine tank areconnected to metering means operable to periodically and simultaneouslydeliver separately controlled streams from the respective tanks to acombined pickle line where they are combined and then cooled. Coolingmeans and also storage means are provided for the combined pickleformula.

Further objects and advantages of the present invention will be madeknown by the following detailed disclosure when read in conjunction withthe drawing wherein:

The single FIGURE is a schematic representation of a preferred system ofapparatus of the present invention.

According to a preferred method of the present invention a largequantity of solid salt (sodium chloride NaCl) is maintained in areplenishable body of water, commonly known in the trade as a lixator,to produce a saturated brine solution, a large quantity of which ispumped to a storage zone. Also a supply of liquid sugar or dextrose issimilarly maintained, however the liquid sugar or dextrose is held at atemperature sufficient to maintain a non-crystalline liquid which isusually between 122 F.-135 F., preferably 125 F-l 30 F. At highertemperatures there is a tendency for carmelization to occur. Preferablythe liquid sugar or dextrose is a solution containing approximately68-69 percent solids such as product No. 2606 (68.0-69.0 percent solids,31-32 percent moisture, pH 4.5-5.1, ppm iron 4.0 maximum, and dextroseequivalent 99.5 minimum) supplied by the Corn Products Company.Periodically, as required, a measured amount of the liquid sugar ordextrose is introduced into a measured quantity of water placed in amixing zone and the two liquids are agitated. Preferably, thetemperature of the water supply may be adjusted as for instance, bycombining streams from hot and cold water sources. A preferredtemperature for the water introduced into the' mixing zone is 50 F.- F.Warmer water temperatures in that range tend to facilitate thedissolving of the additional ingredients.

While the liquid sugar or dextrose and water are being agitated,carefully measured weights of such additional ingredients are alsointroduced into the mixing zone. These include a phosphate salt such astripolyphosphate and curing salts such as sodium erythorbate and sodiumnitrite. The latter two items may advantageously be dissolved in smallquantities of water prior to being introduced into the mixing zone.

The water, liquid sugar or dextrose, and curing ingredients areapportioned and mixed together sufficiently to produce a desiredquantity of a dose: mix of a recipe suitable for subsequent combiningwith saturated brine in a controlled ratio. A preferred formulation ofingredients of such a dose mix to produce a quantity of about 837 .8gallons is as follows:

Water 5,311 lbs. (637.73 gallons) Dextrose (68-69% solids) 2,191 lbs.(200.09 gallons) Tripolyphosphate (Curafos) 750 lbs. (Dry) Sodiumerythorbate 50 lbs. (in solution) Sodium nitrite 30 lbs. ozs. (Insolution) Separately controlled streams of each of such dose mix andsaturated brine are periodically and simultaneously withdrawn from hemixing zone and storage zone, respectively, at rates that areproportional to one another according to a desired ratio. Preferablyeach of the streams is strained to remove solid particles. A desiredfinished pickle formula utilizing the foregoing preferred dose mixformulation will require two parts of saturated brine to each part ofthe dose mix (however any other ratio may be selected to give a finishedpickle that may be desired). Accordingly, the abovedescribed quantity ofdose mix will be sufficient, when mixed with brine in the amount of16,667 lbs. (1,662.24 gallons) to produce a total of 2,500 gallons offinished pickle. However, according to the present method the period oftime consumed for the production of that total quantity can be adjustedto almost any requirements.

The two separate streams of dose mix and saturated brine aresubsequently merged into a single flow of finished pickle formula whichis promptly thereafter cooled to about 35 F. A volume of the cooledpickle is preferably stored in a holding zone against the operationaldemands for the liquid in curing operations such as the stitch pumpingof bacon and/or the artery pumping of hams, etc. Upon such demand,needed amounts of the cooled pickle are withdrawn by pumping from theholding zone, and the withdrawn pickle formula is constantlyautomatically tested for specific gravity to assure that the desiredformulation is being maintained. The preferred pickle formula, accordingto the abovedescribed dose mix and brine requirements, will have adensity of 9.97 lbs. per gallon. Additionally, accuracy of the pickleformulation can be maintained by monitoring the flow rates of each ofthe separately controlled streams of dose mix and saturated brine.

A preferred system of apparatus for practicing the foregoing method isshown in the single figure wherein a salt-dissolving tank (salt lixator)10 adequate to maintain carload quantities of salt (NaCl) is serviced bya waterline 11 and is connected to a brine storage tank 12 by a brineconduit 13 and brine pump 14. The dose mix is prepared in a mixing tank17 provided with a cold water supply line 18, hot water supply line 19and mixing valve 20. A liquid sugar or dextrose supply tank 23sufficient to contain 35,000 lbs. of liquid sugar or dextrose contains aheater 24, which may be either steam or electric, and is connected todeliver liquid sugar or dextrose to the mixing tank 17 by a liquid sugaror dextrose conduit 25 and liquid sugar or dextrose metering pump 26.

The mixing tank 17 is provided with an electrically powered agitator 28having paddles or blades (not shown) disposed in the lower portion ofthe tank.

Delivery means for adding additional ingredients into the mixing tankare preferably a hopper 30 and a screw conveyor 31 powered by anelectric motor 32. Preferably measured quantities of dry ingredients arefirst placed into the hopper 30 and after liquid sugar or dextrose andwater have been premixed in the mixing tank 17 the motor 32 is energizedto gradually feed the solids through screw conveyor 31, into the mixingtank.

Separate streams of brine and dose mix are withdrawn from the respectivestorage tank 12 and mixing tank 17 by means such as a metering pumpgenerally 35 which is provided for dual output. Such a metering pumpincludes a common drive unit 36 and separate brine pump 37 and dose pump38. Each of the latter pumps are preferably of the positive displacementtype and are driven by variable speed connections so that the ratio ofoutput of each pump can be carefully controlled. Several suitablemetering pumps of this type are available commercially.

The brine pump 37 is connected to the storage tank 12 by means of a lowpressure brine line 51. The brine line 51 is provided with a pluralityof parallel arranged strainers 52 to separate solids from the brine. Itis also provided with a three-way valve 53 for purposes of cleanup andsanitation. The three-way valve 53 is placed between the strainers 52and the brine pump 37 and includes an actuator 54 and a quick disconnecthot water line 55 for selectively introducing flush water downstream ofthe valve.

The mixing tank 17 is similarly connected to the dose pump 38 by meansof a low pressure dose line 58 which also includes parallel strainers 59and a three-way valve 60 placed between the strainers and the dose pump38. The latter valve also includes an actuator 61 and a quick disconnecthot water line 62 for selectively introducing flush water into thesystem downstream of the three-way valve 60.

Metered brine expelled from the brine pump 37 travels through a brinedelivery line 65 to which is mounted a pulsation dampener 66 closelyadjacent the pump 37. Beyond the dampener is located another three-wayvalve 67 having an actuator 68 and a recycle line 69 which selectivelyreturns brine to the storage tank 12. However, the brine delivery line65 also extends beyond the valve 67 and includes a flow meter 70.

Similarly, the metered stream of dose mix expelled from dose pump 38travels through a dose delivery line 73 also provided with a pulsationdampener 74 and a three-way valve 75. The latter valve 75 includes anactuator 76 and a recycle line 77 to selectively return dose mix to themixing tank 17.

It may also be noted that each of the aforementioned recycle linesincludes further three-way valves actuatable to be connected to therespective tank or to drains. When cleaning the system, hot waterintroduced at either of the three-way valves 53 and 60 is directed for aportion of time through the respective recycle lines 69 and 77 anddirected into a sewer, but wash water is not normally directed intoeither storage tank 12 or mixing tank 17.

The liquid streams in brine delivery line 65 and dose delivery line 73are combined at a flow means comprising a T connector 80 and a singlepickle line 82 which contains a pressure regulator valve 83 set tomaintain a positive pressure of about 30 p.s.i. at the discharge sidesof pumps 37 and 38.

The pickle line 82 is directed into a heat exchanger 85 which is alsoserviced by a cooling medium such as ammonia or chilled brine from acooling source, not shown. The heat exchanger 85 is selected of asufiicient size to provide a residence time for the pickle formulasufficient to obtain complete intermixing of the brine and dose mix andto reduce the temperature of the combined fluid flow to about 35 F.Beyond the heat exchanger 85 the pickle line 82 extends through athree-way valve 87, provided with an actuator 88 and a connection to adrain 89, and into a pickle holding tank 92.

During cleanout operations for a portion of the time that water isintroduced through three-way valves 53 and 60, it is directed throughthe brine delivery line 65, dose delivery line 73, T connector 80,pickle line 82 and heat exchanger 85 and into the drain 89 through valve87. Wash water is not normally directed into the pickle holding tank 92.

The pickle holding tank 92 is further provided with a discharge supplypipe 93 and pump 94 actuated on demand for the pickle formula insubsequent curing operations. The supply pipe 93 is also provided withspecific gravity (density) measuring means 95 to analyze the finishedliquid for proper composition. Should the composition deviate fromlimits established, the density measuring means 95 initiates an alarmcalling attention of an operator to the need for either an adjustment inthe metering pump generally 35 or in the quantities of ingredients goinginto the dose mix. Such an alarm condition may also automaticallydeenergize the pump 94 to cease discharge of the pickle and/or recyclethe pickle to the holding tank 92.

Also the pickle holding tank 92 is provided with a liquid level sensingunit 97 which is electrically connected to control the drive 36 ofmetering pump generally 35. When the sensing unit 97 detects that thepickle storage tank is substantially full, the metering pump generally35 is caused to be deenergized; and when the sensing unit detects thatthe level of liquid in holding tank 92 has fallen beneath a presetlevel, the metering pump is reenergized so as to refill the storagetank. In addition, it is advantageous to provide the storage tank 12 andmixing tank 17 with indicator means (not shown) sufficient to callattention of an operator to the respective liquid levels should theyreach a nearly depleted condition.

Obviously many modifications and variations of the invention ashereinbefore set forth may be made without departing from the spirit andscope thereof, and, therefore, only such limitations should be imposedas are indicated in the appended claims.

I claim:

1. An improved method for manufacturing a curing pickle solution, saidmethod comprising: continuously dissolving salt and storing a quantityof saturated brine; maintaining a supply of one of liquid dextrose andsugar in non-crystalline form at a temperature up to F.; agitating ameasured amount of one of said dextrose and sugar in a measured quantityof water in a mixing zone; adding to said mixture in said zone measuredweights of additional pickle formula ingredients while continuing saidagitation to produce a dose mix; simultaneously withdrawing separateregulated streams of brine and dose mix; combining said streams in adesired ratio to produce a single flow of pickle solution; continuouslychilling said single flow of pickle solution to about 35 F.; and storingsaid solution in a holding zone.

2. The method of claim 1 wherein amounts of the stored pickle solutionare periodically pumped from said zone to curing operations and testedfor specific gravity.

3. The method of claim 1 wherein said additional ingredients comprisetripolyphosphate salt, sodium erythorbate and sodium nitrite.

4. The method of claim 1 wherein said separate streams of brine and dosemix are strained.

1. An improved method for manufacturing a curing pickle solution, saidmethod comprising: continuously dissolving salt and storing a quantityof saturated brine; maintaining a supply of one of liquid dextrose andsugar in non-crystalline form at a temperature up to 135* F.; agitatinga measured amount of one of said dextrose and sugar in a measuredquantity of water in a mixing zone; adding to said mixture in said zonemeasured weights of additional pickle formula ingredients whilecontinuing said agitation to produce a dose mix; simultaneouslywithdrawing separate regulated streams of brine and dose mix; combiningsaid streams in a desired ratio to produce a single flow of picklesolution; continuously chilling said single flow of pickle solution toabout 35* F.; and storing said solution in a holding zone.
 2. The methodof claim 1 wherein amounts of the stored pickle solution areperiodically pumped from said zone to curing operations and tested forspecific gravity.
 3. The method of claim 1 wherein said additionalingredients comprise tripolyphosphate salt, sodium erythorbate andsodium nitrite.